Noob fixes horrible gas tank.

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Hi all,I'm both new here and really new to welding. I have a flux core welder that I've been using to do small repairs around the house. But this will be my first real welding project.So a while back, my buddy Jake asked if I could repair his old gas tank. He recently bought his dream bike, a 1984 Kawasaki Ninja ZX900. Unfortunately, the gas tank is shot, and he can't afford to replace it. Since I'm into weird projects and learning new things, I offered to repair it for him. Of course, before I started cleaning it out, I didn't know quite how far gone it was. I started by tumbling it with nuts and bolts inside to try to knock the loose rust out, and then soaked it in vinegar for a month. The cleaner it got, the more pinholes I found. I got nearly a quart of rust out, not including all the dust and mud that I got while washing it out with water.

Unfortunately, it was just not getting the rust out, so on the advice of another fellow, I cut the bottom out so I could physically get to it all with a wire wheel. I also stripped the paint. It was all bubbled up anyway.


It took a while, but I finally got down to shiny metal.


So now I'm committed to welding it back together eventually. I've been using my flux core welder to try to replace thin sections and fill holes, but it's slow going. I keep making new holes to fill, LOL. I've also tried brazing, but I can't seem to get a hot enough flame to melt the brazing rod. I have MAPP gas and a torch, but it doesn't seem hot enough. I bought an oxy/MAPP torch, but I can't find oxygen canisters.Just today, I visited a welding supply store, and they are willing to sell me a refillable oxygen tank. I just have to figure out how to connect it to the torch. They're also willing to sell me argon. Which is good because someone told me that TIG welding is better for thin sheet metal than flux core welding is.Right now, I'm taking a bit of a break, and researching TIG welding, and seeing how to safely connect a large oxygen tank to a brazing torch. By large though, I mean a 20 cu. ft. tank vs. the little 1.4L cylinders that are meant to be used.Last edited by Rebelrider.Mike; 1 Day Ago at 10:46 PM.
Reply:You are wasting your time trying to fix thatSent from my SM-G996U using TapatalkMillermatic 252 MIGMiller Dynasty 200DX TIGMiller Spectrum 625 PlasmaAltas 12x36 Metal LatheBridgeport Milling Machinewww.psacustomcreations.com
Reply:

Originally Posted by psacustomcreations

You are wasting your time trying to fix thatSent from my SM-G996U using Tapatalk
Reply:

Originally Posted by psacustomcreations

You are wasting your time trying to fix thatSent from my SM-G996U using Tapatalk
Reply:Let me expand on why you should not do this repair.Are you willing to put yourself at risk of a lawsuit when, not if, this leaks?Gas will seep through the most minute cracks or holes.There will be gas seeping through the holes onto the person and hot engine. = Not good. Most every time you try to fill one hole, another will appear. Once you try to grind the weld flush, a hole will appear. Every weld will start to distort the metal. Can you shape it back to normal?How many days of work are you willing to spend? At your skill level, I do mean days not hours  Sent from my SM-G996U using TapatalkMillermatic 252 MIGMiller Dynasty 200DX TIGMiller Spectrum 625 PlasmaAltas 12x36 Metal LatheBridgeport Milling Machinewww.psacustomcreations.com
Reply:DON'T DO IT!!!!!Your friend is not a friend if he's asking you to do this. It's an impossible job, doomed to failure. He can't afford to buy a better tank, but he's asking you without adequate skill, or adequate welder to spend days fixing this disaster.This is a real stretch for an expert welder, maybe Jesse James could do it. I'll bet any expert would start over with new metal. They'd use a TIG welder.Most experts wouldn't try at all unless it is a custom bike they can't buy a factory tank for.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:

Originally Posted by Willie B

DON'T DO IT!!!!!Your friend is not a friend if he's asking you to do this. It's an impossible job, doomed to failure. He can't afford to buy a better tank, but he's asking you without adequate skill, or adequate welder to spend days fixing this disaster.This is a real stretch for an expert welder, maybe Jesse James could do it. I'll bet any expert would start over with new metal. They'd use a TIG welder.Most experts wouldn't try at all unless it is a custom bike they can't buy a factory tank for.
Reply:

Originally Posted by Lis2323

In all probability the friend is only guilty of being ignorant. Sent from my iPad using Tapatalk
Reply:

Originally Posted by 12V71

I have "friends" that think mechanic/welder means "magician".
Reply:

Originally Posted by Lis2323

in those cases do your very best to make their cash “disappear”
Reply:Which is good because someone told me
Reply:IMO, your ONLY hope of sealing this is going to be to weld it back together, PROPERLY, after welding get a commercial gas tank sealer and dose the tank with it per instructions, then kick yourself in the A$$ for taking on such a job. The other option is to find a custom bike builder and have a new tank fabricated, a good fabricator can do it, that's what I would do. Personally I'd back out & tell him it's not worth the effort OR liability.NRA LIFE MEMBERUNITWELD 175 AMP 3 IN1 DCMIDSTATES 300 AMP AC MACHINELET'S GO BRANDON!"Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” BENJAMIN FRANKLIN
Reply:I primarily do thin stainless Tig welding that easily fits into this type of work. This isnt a repair job for just anyone. Like everyone else has said, that repair will cost the same as a new tank. Once you cut something like that apart, you released the stress from shaping. If it wasnt a PITA then, it will be now making it look nice.